|Número de publicación||US8177117 B2|
|Tipo de publicación||Concesión|
|Número de solicitud||US 12/323,821|
|Fecha de publicación||15 May 2012|
|Fecha de presentación||26 Nov 2008|
|Fecha de prioridad||15 May 2008|
|También publicado como||US20090286663|
|Número de publicación||12323821, 323821, US 8177117 B2, US 8177117B2, US-B2-8177117, US8177117 B2, US8177117B2|
|Cesionario original||York Container Company|
|Exportar cita||BiBTeX, EndNote, RefMan|
|Citas de patentes (81), Citada por (6), Clasificaciones (31), Eventos legales (1)|
|Enlaces externos: USPTO, Cesión de USPTO, Espacenet|
This application is a continuation-in-part of prior U.S. patent application Ser. No. 12/121,414, filed on May 15, 2008 now U.S. Pat. No. 7,819,305, the entirety of which being incorporated herein by reference. The invention relates in general to the manufacture of packaging/containers that may be readily used to transport product and/or display the contents of the containers following delivery, as specified in the independent claims.
Various packages and containers are conventionally provided for transporting product to and storing product in a retail environment and for display to prospective customers. As is conventionally known in the packaging industry, such containers can be transported to manufacturing and/or retail environments for display in knock-down form, i.e., flattened but otherwise being glued, stapled or otherwise affixed or joined together, such that they are already substantially pre-assembled; in such a knock-down state, personnel assembling the container need only open the sides and or ends of the container and affix the container bottom wall into its assembled condition. As a result, such final assembly may be performed prior to loading manufactured product. Alternatively, such final assembly may be performed such that the product can be placed into a resulting assembled container for ready display.
Conventionally, it has been deemed advantageous at times to stack a plurality of such containers, one on top of the other, for the purposes of transport to a retail environment or during display in the retail environment. In this use, it is necessary that the containers stacked above the bottom-most container are amply supported and also that a stack of a number of such containers, when loaded with product, will not collapse.
The following presents a simplified summary in order to provide a basic understanding of some aspects of various invention embodiments. The summary is not an extensive overview of the invention. It is neither intended to identify key or critical elements of the invention nor to delineate the scope of the invention. The following summary merely presents some concepts of the invention in a simplified form as a prelude to the more detailed description below.
In accordance with illustrated embodiments, a method of manufacturing containers and resulting containers and associated pre-assemblies and blanks are provided, which, when utilized, result in a container that has increased side panel strength and corner strength so as to enable effective vertical stacking of containers when the container includes product.
Additionally, in accordance with some illustrated embodiments, the manufactured container provides the dual use of both a transporting container for transporting product to a retail environment and a display container configured to display the product in that retail environment.
Various embodiments are described herein, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings, it should be understood that the particulars shown are by way of example and for purposes of discussion of illustrated embodiments only, and are presented in order to provide what is believed to be a useful and readily understood description of the principles and concepts of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the illustrated embodiments, the description taken with the drawings making apparent to those skilled in the art how the several illustrated embodiments of the invention may be embodied in practice.
Accordingly, a more complete understanding of the present invention and the utility thereof may be acquired by referring to the following description in consideration of the accompanying drawings, in which like reference numbers indicate like features, and wherein:
In the following description of various invention embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown, by way of illustration, various embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope and spirit of the present invention.
The manufacture and use of containers that may be used for more than one purpose, e.g., for transport of product and subsequent display of product in a retail environment, are becoming increasingly popular among both manufacturers and retailers because such containers enable a reduction or minimization of the amount of container material while increasing or maximizing the amount of display space available for product. Thus, it is conventionally known that blanks (e.g., made from some type of paperboard and/or other material that is die-cut and scored for subsequent manipulation to form a pre-assembly), pre-assemblies (e.g., a partially assembled container wherein the blank(s) is manipulated and affixed to itself but is not finally assembled) and containers (e.g., packaging, cartons, boxes, etc.) may be provided that enable product to be transported to a retail environment in a transporting container and displayed in the retail environment within the transporting container following minor modification of the container.
The durability, strength and stackability of such packaging often require increasing the amount of material content within the container. However, further reducing the amount of material content within containers has become a significant goal of many manufacturers and retailers because of the adverse effect that container has on landfills and the environment in general as well as the cost of manufacturing, transporting and disposing of such containers.
Thus, both manufacturers and retailers are recognizing a need to reduce the amount of containers used to provide product to an end-consumer in a retail supply chain in an effort to conserve natural resources, reduce an impact on the environment and reduce costs associated with product manufacture and sale. In an effort to achieve these goals, various initiatives have been put in place by both suppliers and retailers to reduce overall product container by some percentage, e.g., five percent.
One conventional mechanism for reducing the amount of containers necessary to provide product to potential consumers in a retail environment is by providing dual-use containers wherein a container can be used both to contain product during transporting and also to display the product once that product has arrived in a retail environment, e.g., a store or other environment offering product for sale.
Further, in an effort to further use available space in a retail environment, retailers may be interested in using the display function of such dual-use containers in a manner such that containers may be stacked on top of one another to improve or optimize vertical space utility in the retail environment. Simply put, having the ability to be able to stack display cartons enables a store operator to present more product and/or different types of product in a manner that a customer can see. For example, by providing the opportunity to stack such containers, e.g., display cartons, on a counter, a store operator is able to increase the use of counter space such that more than one carton can occupy the same horizontal counter foot print. As is understood in the retail industry, such a configuration increases sales because customers are able to see more available product and product types for sale.
However, a problem with stacking such display cartons and shipping cartons, whether such packaging is dual-use transporting/display containers or otherwise, is that the weight of the carton(s) in combination with the weight of the product(s) stored in the container(s) can cause one or more containers to be damaged or collapse. As a result, a store operator is left with damaged, ineffective or completely non-functioning display container(s), which causes operational problems and reduces likelihood of sales to consumers.
Accordingly, based on all of these factors, there is a need to provide a method of manufacturing reduced material content containers and resulting containers and associated pre-assemblies and blanks, which, when utilized, result in a container that has significantly improved stacking strength over conventional containers and optionally provides the dual use both as a transporting container for transporting product to a retail environment and a display container configured to display the product in that retail environment. With this understanding of one area of packaging/container utility in mind, a description of various invention embodiments is now provided.
According to as least one illustrated embodiment, there is provided equipment configured to manufacture shipping containers, display containers and/or dual-use containers, e.g., for transporting product and subsequent display of the product (as well as corresponding container pre-assemblies and blanks) that include a reduced amount of material content while maintaining or increasing the stacking strength of such containers. In view of recent retailer initiatives to reduce the amount of material content in containers, such containers may have increased utility to manufacturers and retailers. Thus, providing containers with reduced material content would be of increased value. Additionally, because of the unique structure provided in accordance with the illustrated embodiments, side wall strength is increased as well.
Additionally, based on the illustrated examples of container designs provided with auxiliary corner supports as disclosed herein, it should be appreciated that the incorporation of the corner supports also increases stackability of the resulting containers without requiring a lengthier time period for final assembly and without a need for assemblers (either human or automated or semi-automated equipment) to have superior capabilities. This is because, as explained herein, the majority, if not all, of manipulation of the preassembly to form the auxiliary corner supports is already performed as part of the final assembly of the primary blank as the exterior of the container. As a result, the additional operations needed to provide the corner supports is reduced or eliminated relative to what would be conventionally required for installing or assembling conventional auxiliary corner supports.
Understanding of the manufacturing of a container, blanks and/or pre-assemblies in accordance with invention embodiments may best be understood by first reviewing an illustration of a manufactured container provided in accordance with one illustrated embodiment. As illustrated in
As part of manufacturing a pre-assembly for the container illustrated in
The two access openings 145 may be formed by removing additional material (not shown) to provide the access openings (as illustrated in
The blank 101 may also include scored holes 155 for enabling an individual to carry the container 100 once finally assembled. Alternatively, as illustrated in
As part of manufacturing of the pre-assembly for container 100, a section 160 of the supplementary blank 103 is affixed to one or both of the interior faces of the side panels 105, 115. The faces may be affixed in one or more suitable manners including application of adhesive on one or both of the affixed faces, use of staples, tape, etc. At least a portion of the central section 160 of each of the blanks 103 is affixed to one of the side panels 105, 115, thereby leaving the support sections 102 to remain free to bend back towards the interior of the container 100 following final assembly. Accordingly, the auxiliary support sections 102 are bent back towards the interior of the container 100 and make contact with the neighboring sides of the primary blank 101, e.g., the front panel 120 and/or the back panel 110A-B (as illustrated in
Thus, following final assembly, the container 100 is thus formed in a rectangular configuration, with the side panels 105, 115 and back panels 110A-B and front panel 120 forming a pair of opposing walls. Further, the container 100 includes both increased strength on the side panels by the central section 160 of blank 103 affixed to the side panels 105, 115 and the inclusion of the auxiliary support sections 102 at the corners of the container 100, wherein the various side panels intersect. Therefore, it should be appreciated that this embodiment provides a plurality of auxiliary support sections 102 extending diagonally across respective corners of the container 100 planarly.
Pre-assembly is normally performed at a container manufacturing facility to produce a pre-assembly, which may also be thought of and referred to as a knock-down of the container. These pre-assemblies may be shipped to a customer location such as a product manufacturing facility. At the product manufacturing facility, the customer may perform final assembly/use of the containers by, for example, folding and assembling various panels of the container to provide a container that is configured to hold manufacture product, e.g., for shipping and/or display.
In such operations, the labelling of the resulting containers may be performed by the customer of the pre-assemblies and/or as part of manufacture of the pre-assemblies as illustrated in
Subsequent to blank manufacturing 715, multi-blank pre-assembly operations may be performed in various suitable manners by hand or using various commercially available machines (for example, those produced by Bahmueller Technologies, Inc. of Charlotte, N.C., USA or Bobst Group North America of Roseland, N.J., USA), to produce pre-assemblies for reinforced containers such as that illustrated in
Thus, at the beginning of such operations, raw material 725 is used to produce blanks 730. Such raw materials 725 may include but are not limited to various grades, types, configurations and combinations of corrugated fiberboard and/or solid paperboard, liner board, board of various fluting types and combinations as well as various types of sealants, non-organic materials and inks and dies of various suitable types.
It should be understood that implementation of the method and system of the present invention involves performing or completing certain selected tasks or steps manually, automatically, or a combination thereof.
While the invention has been initially described in conjunction with the specific embodiments outlined above, it should be evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the various embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention. Thus, it should be understood that containers come in many different varieties but most packaging containers can be folded and assembled from a flat form, known as a blank or pre-assembly. Accordingly, it should be understood that the pattern for any blank, pre-assembly or container may be different than those initially described herein.
As illustrated in
As explained in connection with
A display cut-out 245 may be provided in the front panel 220 of the primary blank 201; accordingly, although not shown the cut-out may be formed when a perforation is used to remove material (not shown) from the container 200 so as to provide an access opening for ready access to product displayed in the container 200. This opening 245 may be in communication with the open top end of the container 200, which (during use as a display) may be free of any top wall or panel following modification of the container 200 for the display function of the dual-use container. It should be appreciated that the opening 245 may be omitted, for example, if the container is to be used only as a shipping container.
For example, one central section (e.g., 260B) of the central sections 260A-C or two non-neighboring central sections (e.g., 260A, 260C) may be affixed to the blank 201; however, particular utility may be provided by affixing the two non-neighboring central sections 260A and 260C to the primary blank 201 via adhesive 213 (illustrated in
It should be appreciated that the primary blank 201 and the supplementary blank 203 may be affixed to one another at various different locations to form a pre-assembly. For example, only one central section (e.g., 260B) of the central sections 260A-C of the supplementary blank 203 may be affixed to a corresponding location (e.g., panel 210) of the primary blank 201. Alternatively, two non-neighboring central sections (e.g., 260A, 260C) of the supplementary blank 203 may be affixed to the corresponding panels (e.g., panels 205, 215 respectively) of the primary blank 201. Thus, as part of pre-assembly manufacturing, one or more of the central sections 260A-C of the blank 203 is affixed to one or more of the interior faces of the side panels 205, 210, 215. Regardless of which configuration for affixing the primary and supplementary blanks 201, 203 is used, the opening of the pre-assembly 200 results in the support sections 202A-D extending diagonally along the corners of the container 200 during final assembly of the container 200 from the pre-assembly.
The faces of the primary and supplementary blanks 201, 203 may be affixed to each other in one or more suitable manners including application of adhesive on one or both of the affixed faces, use of staples, tape, etc. However, of particular utility may be the use of adhesive to attach the blanks 201, 203 together; such an adhesive may be selected from various different types of adhesives that enable varying speeds of set times and strengths of adherence. For example, the blanks 201, 203 may be adhered to one another using an adhesive that may be what is referred to in the packaging industry as a “cold-set” adhesive, meaning that the adhesive is not heated prior to application. Such adhesives generally take longer to set, i.e., provide adherence of the materials being joined; however, such adhesives also generally provide a relatively strong bond. Cold-set adhesives differ from what are referred to as “hot-melt” adhesives, which generally set relatively faster but provide a relatively weaker bond.
Thus, it should further be appreciated that cold-set adhesives provide for the ability to alter positioning by, for example, a lateral sliding movement, immediately following initial contact between the blanks 201, 203. Therefore, it should be understood that the folding operations performed as part of pre-assembly manufacture and explained herein with reference to
Thus, as shown in
As a result, as shown in
As shown in
As shown in
Following folding of the panels of the primary blank 201, the front panel 220 comes into contact with the adhesive panel 240, which may be carrying some type of adhesive (not shown) so as to adhere the edge of the front panel 220 to the edge of the side panel 215. As a result of these folding operations and the adherence between the blanks 201, 203, the pre-assembly illustrated in
Thus, as illustrated in
As a result of this cooperation of the components of blanks 201 and 203 one or more optional air cells 270 may be created in the container 200 as illustrated in
Like the other illustrated embodiments, the container 300 is formed by the joining of a primary blank 301 (as illustrated in
As shown in
The blank 301 also includes four bottom sub-panels 330 that cooperate to form a bottom of the container 300 following final assembly as well as two types of top sub-panels 375, 380. The sub-panels 375 differ from the sub-panels 380 in that the sub-panels 380 include a perforation line 385 that lines up with the perforation lines corresponding to the cut-out 345 when the container 300 is finally assembled. The cooperation of the perforation lines 385 and the perforation for the cut-out 345 provide the ability to provide an access opening in the container 300 when the container is used as a display container. To that end, the cut-out 345 may optionally include an aperture or aperture perforation 395 that further enables easy removal of the cut-out 345 and portions of the top sub-panels 380.
Accordingly, the supplementary blank 303 includes an end section 360A and a central section 360B that serve as locations for affixing the blanks 301, 303 together. Thus, in an illustrated embodiment, the end section 360A includes adhesive 313A and the central section 360B includes adhesive 313B for affixing the sections 360A, 360B to the primary blank 301. As shown in
As illustrated in
It should be understood from
Thus, when the pre-assembly 300 is finally assembled, as shown in
Like the other illustrated embodiments, the container 400 is formed by the joining of a primary blank 401 (as illustrated in
As shown in
The primary blank 401 also includes the constituent panels for the rectangular shaped, truncated corner supports 404. More specifically, corner support 404A includes two panels 490A, 491A separated by a fold line 492A and sharing a bottom perforation line 493A; likewise, corner support 404B includes two panels 490B, 491B separated by a fold line 492B and sharing a bottom perforation line 493B. Note, the fold line 411A between the end panel 410 and the side panel 405 does not line up with the fold line 492A. Likewise, the fold line 411C between the side panel 415 and the front panel 420 does not line up with the fold line 492B.
As illustrated in
As noted above and should be understood from
As in other illustrated embodiments, the diagonal corner supports 402 are formed by the sizing of the support sections 402 and the positioning of the support sections 402 so that the fold line 465 for each blank 403 is offset from the fold lines 411B or 411D (depending on which supplementary blank 403 is being considered).
Subsequent to the folding over of the side panel 415 along fold line 411C and folding over of the end panel 410 along fold line 411A, adhesive carried on the adhesive panel 440 is used to join the side and end panels 410, 415 to one another and provide the completed pre-assembly 400 as shown in
When the pre-assembly 400 is finally assembled, as shown in
Like the other illustrated embodiments, the container 500 is formed by the joining of a primary blank 501 (as illustrated in
As shown in
The blank 501 also includes two of each of two types of bottom sub-panels 530, 531, the two types differing in size but cooperating to form a bottom of the container 500 following final assembly. The primary blank 501 also includes two of each of two types of top sub-panels 575, 580, the two types differing in that the sub-panels 585 include perforation lines 585. The panels 575, 580 cooperate to form a top of the container 500 following final assembly. As in the embodiment illustrated in connection with
Like the embodiment illustrated in
As illustrated in
As noted above and should be understood from
As shown in
When the pre-assembly 500 is finally assembled, as shown in
Thus, the support panels 508 are formed to replace the conventional container corners and provide added stacking strength for the container 500. Likewise, the diagonal supports sections 502 are formed in the remaining, opposing corners by the force imposed on the support section 502 of each of the supplementary blanks 503 when the primary blank panels are configured as the exterior of the container 500.
Therefore, it should be appreciated that this embodiment provides at least one auxiliary support section 502 of the supplementary blank 503 extending diagonally across at least one corner of the container 500 planarly and the container 500 includes at least one other auxiliary support panel 508 that extends diagonally across at least one corner of the container 300 planarly.
It should be understood that invention embodiments are capable of variations practiced or carried out in various ways. Therefore, it should be appreciated that, in accordance with at least one embodiment of the invention, any and all of the walls may be constructed of corrugated cardboard. However, it should be understood that the walls, panels, any tabs on various panels, etc., may be constructed of various industry recognized appropriate materials that meet various transporting and/or display criteria. As a result, it should be understood that containers manufactured in accordance with at least one embodiment of the invention may also be considered “cartons,” which may be considered packaging containers, commonly made from cardboard.
It should also be understood that illustrated invention embodiments may result in pre-assemblies that may be finally assembled for use as containers using conventionally known auto-erector machinery that finally assembles containers with minimal or no human operator involvement.
Alternatively, or more specifically, the packaging containers may be made using corrugated board, e.g., material made by a corrugator (a machine that produces corrugated board by attaching fluting to liners) which is a structured board formed by gluing one or more arched layers of corrugated medium to one or more flat-facing linerboards.
Additionally, it should be appreciated that material used in accordance with at least one embodiment of the invention may be laminated to provide barrier properties. Further, other barrier materials may be used including Ultra Violet (UV), moisture and gas barriers. Additionally, though not discussed in great detail herein, it should be understood that any adhesive used to provide a bond between materials used in containers provided in accordance with the invention may include any substance that helps bond two materials together, examples including but not limited to glue and paste.
It should also be appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.
Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention.
Additionally, it should be understood that the functionality described in connection with various described components of various invention embodiments may be combined or separated from one another in such a way that the architecture of the invention is somewhat different than what is expressly disclosed herein. Moreover, it should be understood that, unless otherwise specified, there is no essential requirement that methodology operations be performed in the illustrated order; therefore, one of ordinary skill in the art would recognize that some operations may be performed in one or more alternative order and/or simultaneously.
As a result, it will be apparent for those skilled in the art that the illustrative embodiments described are only examples and that various modifications can be made within the scope of the invention as defined in the appended claims.
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|US20080265726||25 Abr 2007||30 Oct 2008||Sheffer Phil B||Folded and glued display container having integral shelf elements|
|US20100083618||8 Abr 2010||York Container Company||Materials for and method for manufacturing container with stacking shoulders and resulting container|
|FR2641758A1||Título no disponible|
|Patente citante||Fecha de presentación||Fecha de publicación||Solicitante||Título|
|US8297490 *||1 Abr 2010||30 Oct 2012||York Container Company||Materials for and method for manufacturing a container with corner supports and the resulting container|
|US8510877 *||21 May 2008||20 Ago 2013||Cleanis Company||Toilet device of the pierced chair type including a box designed from a pre-cut planar blank and a collection bag|
|US8622282 *||19 Feb 2010||7 Ene 2014||Rock-Tenn Shared Services, Llc||Blanks and methods for forming reinforced containers|
|US20100180370 *||21 May 2008||22 Jul 2010||Cleanis Company||Toilet Device of the Pierced Chair Type Including a Box Designed from a Pre-Cut Planar Blank and a Collection Bag|
|US20100288670 *||18 Nov 2010||Innovative Packaging Designs, Lp||Container having sliding corner support|
|US20110204131 *||19 Feb 2010||25 Ago 2011||David Joe Brundage||Blanks and methods for forming reinforced containers|
|Clasificación de EE.UU.||229/120.18, 493/96, 493/89, 493/907, 229/122.32, 493/94, 229/199|
|Clasificación internacional||B31B17/00, B31B7/00, B65D25/04, B65D5/50|
|Clasificación cooperativa||B31B2201/26, B65D5/445, B65D5/16, B65D5/566, B31B2217/0007, B31B2201/28, B31B1/76, B31B2203/003, B31B17/00, B31B2217/086, B31B1/26, B65D5/3621, Y10S493/907|
|Clasificación europea||B65D5/36B2A, B31B1/26, B31B17/00, B31B1/76, B65D5/44B2, B65D5/56D, B65D5/16|
|1 Dic 2008||AS||Assignment|
Owner name: YORK CONTAINER COMPANY, PENNSYLVANIA
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:LITTLE, TROY;REEL/FRAME:021902/0289
Effective date: 20081126